Optimum Process Parameters for Springback Reduction of Single Point Incrementally Formed Polycarbonate

Many industries and researchers are attempting to minimize manufacturing costs of forming low volume components. Single point incremental forming (SPIF) is used to form a single piece of material using a CNC mill, in which a tool path for the desired geometry is created to guide the tool in incremented steps to deform a thin sheet of material. Throughout this process, residual stresses accumulate; causing springback to occur after the fixture is no longer constraining the material. This research experiments with the effect of SPIF forming parameters on the springback of polycarbonate sheets. Springback reduction was also obtained by applying heat to the formed sheet. The parameters studied included rotational spindle speed, feed rate, step size, and heat. The spindle rotational speed and feed rate experiments show a decrease in springback; however, applying heat proved to be most effective when reducing springback.